Apparatus for making wheel covers



Oct. 2, 1962 G. A. LYON APPARATUS FOR MAKING WHEEL covERs 4 Sheets-Sheet l Original Filed Nov. 5, 1956 l kwil/n Oct. 2, 1962 G. A. LYON APPARATUS FOR MAKING WHEEL covERs 4 Sheets-Sheet 2 Original Filed Nov. 5, 1956 oct. 2, 1962 G. A. LYON 3,056,366

APPARATUS FOR MAKING WHEEL COVERS Original Filed Nov. 5, 1956 4 Sheets-Sheet 5 /2-7VEI7 far-1 650 @GE LBE/Pr you Oct. 2, 1962 G. A. LYON 3,056,366

APPARATUS FOR MAKING wHEELcovERs Original Filed Nov. 5, 1956 4 Sheets-Sheet 4 fra/'Erz fr' 650/? @E /7/.55/97 y0/v by WWWMMMMH//g United States Fatent 3,056,366 APPARATUS FOR MAKHIG WHEEL COVERS George Albert Lyon, Detroit, Mich., assigner to Lyon Incorporated, Detroit, Mich., a corporation of Delaware Original application Nov. 5, 1956, Ser. No. 620,28, now Patent No. 2,942,569, dated June 28, 1960. Divided and this application Dec. 3, 1959, Ser. No. 862,740 4 Claims. (Cl. 113-49) This application is a division of my application 620,288 filed November 5, 1956, now Patent No. 2,942,569.

The present invention relates to apparatus for making Wheel covers of the type used for the ornamental and protective covering of the outer sides of vehicle wheels,

An important object of the present invention resides in the provision of an improved apparatus for making wheel covers with overhanging marginal structure over cover retaining structure carried by the covers.

Still another object of the invention is to provide an improved apparatus for shaping vehicle wheel covers with marginal structure concealingly overlying cover retaining finger structure.

Yet another object of the invention is to provide improved apparatus -for making wheel covers.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a preferred embodiment thereof taken in conjunction with the accompanying drawings in which:

FIGURE l is an outer side elevational view of a wheel structure embodying a Wheel cover made by apparatus of the invention;

FIGURE 2 is an enlarged fragmentary radial sectional detail view taken substantially on the line II-II of FIG- URE l;

FIGURE 3 is a fragmentary side elevational View of the cover;

FIGURE 4 is a fragmentary radial sectional view through a cover blank in an initial stage in the manufacture of a Wheel cover;

FIGURE 5 is a fragmentary outer side elevational view of the cover blank of FIGURE 4;

FIGURE 6 is a radial sectional view similar to FIG- URE 4 but showing the cover blank in a subsequent stage of manufacture;

FIGURE 7 is -a fragmentary, more or less schematic, radial sectional detail view through the cover blank and a forming die apparatus according to this invention for further rforming the cover blank and more particularly the marginal structure thereof after the blank has been shaped to the form shown in FIGURE 6; and

FIGURE 8 is a View similar to FIGURE 7 showing the die apparatus at the completion of the forming operation thereof;

FIGURE 9 is a more or less schematic fragmentary radial sectional detail view through a slightly modified cover blank, such modification being in the marginal axially outwardly projecting rib formation, and a vertical sectional view through forming die apparatus of substantially the same structure and operation as the form die apparatus of FIGURE 7, but modified to accommodate the modified marginal rib formation, and similarly as in FIGURE 7 showing the position of the several parts of the die assembly when the cover blank is fully clamped therein just before the marginal rifb is worked therein;

FIGURE l0 is a vertical, general radial sectional detail View similar to FIGURE 9 but showing the relationship of the die parts and the cover at the completion of the marginal rib Iworking operation or stroke of the apparatus;

FIGURE 1l depicts a radial sectional detail view 3,055,356 Patented Oct. 2, 1962 vertical sectional View through die apparatus similar to the die apparatus of FIGURES 7 and 9 but modified to accommodate the modified marginal rib formation of the cover blank;

FIGURE l2 is a View similar to FIGURE l1 but showing the die apparatus in the relative disposition of the parts at completion of the rib working stroke or operation thereof.

Acover 10 (FIGS. 1 and 2) made in apparatus embodying features of the present invention is constructed and arranged to be applied in press-0n, pry-off relation to the outer side of a vehicle wheel such as an automobile wheel including a disk spider wheel body 11 supporting a tire rim 12. of the multi-flange, drop center type. The tire rim 12 includes an intermediate axially outwardly extending and generally radially inwardly facing flange 13 and a terminal flange 14 which is joined to the axially outer side of the intermediate flange on Va juncture shoulder 15 and extends generally radially outwardly and then axially outwardly. A pneumatic tire 17 is adapted to be supported by the tire rim.

Suitable material from which the Wheel cover lil may be made comprises thin gauge cold work hardenalble sheet brass or stainless steel adapted to be finished by polishing and plating. At its center the wheel cover 10 includes a crown portion 18 for overlying the wheel body 11 and bordered by an annular more or less inwardly dished portion 19 which in the present instance is of substantial Width and may be `substantially straight and sloping slightly axially inwardly. From the radially outer side of the intermediate cover portion 19 is an annular marginal portion 20 diverging generally radially and axially outwardly therefrom and in the present instance preferably in the form of a reinforcing and resiliency imparting rib of substantial width adapted. to overlie the tire rim 12.

At its radially outer extremity, the annular marginal rib portion 20 is of a diameter to overlie the inner portion of the terminal flange 14 inclusive of the juncture 15. Extending integrally in one piece from the extremity of the rib 20 is an underturned generally axially and radially inwardly oblique shoulder flange 21 engageable against the juncture shoulder 15 of the tire rim and by its oblique disposition, diverging from the extremity of the marginal rib 2t), and by virtue of facing generally axially inwardly and radially outwardly, engaging the rim shoulder 15 not only as an axial stop for determining the axially inward disposition of the cover 10 relative to the Wheel, but also serving as a centering frustum in engagement with the rim shoulder.

For retaining the cover 10 against axially outward displacement, the underturned flange 21 has extending therefrom `cover retaining means herein in the form of respective generally axially inwardly extending retaining nger flange extensions 22 of which there may be several, herein four as indicated in dash lines in FIGURE 1. Each of the finger extensions is of substantial width and curved circumferentially so as to be of substantial stiffness against radial deflection. The diameter described by the retaining nger flanges 22 is somewhat less than the inside 4face diameter of the axially outer portion of the generally axially extending intermediate flange 13 of the tire rim.

Juncture of the retaining finger flanges 22 with the underturned flange 21 is on a reinforcing juncture bend 23 which because of its considerable length as best seen in FIGURE 3 and circumferential curvature provides a substantial rigidifying rib enhancing the resilient stiffness yof the finger extensions 22. The length of the reinforcing juncture rib 33 is substantially increased by having the U sides of the finger flanges 22 widely tapering toward juncture with the edge extremity of the underturned fiange 21 intermediate the fingers. Herein four of the fingers 22 are shown but there Vcould be more or less such fingers.

Each of the finger extension flanges 22 is preferably sub-divided by one or more shallow notches or cut-outs 24 into a plurality `of short retaining finger extremities 25 having widely flaring sides joining one another and with the sides of the finger extensions 22 comprising the flaring outer sides of the sidemost retaining finger extremity portions 2S. By suc-h sub-division of the wide finger extention extremity portions ready self-adjustment to manufacturing variables is provided. Each of the finger portions 25 is provided with a retaining terminal in the present instance comprising a generally radially and axially outwardly oblique short and stiff terminal flange 27. All of the terminal flanges 27 project at their tips to a diameter which is somewhat greater than the diameter of the inside face of the axially outer portion of the intermediate flange 13 `so that the terminal edges can engage in gripping biting resiliently tensioned relation against the intermediate flange. For improving the turn-preventing biting engagement of the terminal fianges 27 with the rim flange, each of the terminals is preferably notched out at a plurality of places 28 to afford a plurality of generally circumferentially directed biting corners which bitingly anchor the cover against turning due to rotational torque or torsion in service on the wheel.

In applying the cover 10 to the outer side of the wheel, a valve stem aperture 29 is generally registered with a valve stem 30 and the cover is pressed axially inwardly onto the wheel. This causes the short stiff retaining terminals 27 to `cam axially and radially inwardly along the sloping inner surface of the terminal flange 13 from the rounded juncture shoulder 15. Gradual radially inward deflection of the retaining finger' extremities 25 and the retaining finger iianges 22 occurs until the underturned shouldering flanges 21 seats against the shoulder 15. As a result of the radially inward deflection of the retaining fingers, and the relatively short land stifliy resilient form thereof the underturned oblique seating and centering fiange 21, which is of substantial width and resilience is resiliently deflected generally radially and axially inwardly and may even involve the overlying, concealing resilient marginal rib formation 20` so as to impart substantial and retainingly effective resilient thrust to the retaining terminals 27 for effectively retaining the cover against both axially outward and torsional displacement.

To remove the cover from the wheel, a pry-off tool such as a screwdriver or the like may be inserted behind the underturned seating flange 21 and pry-off leverage applied by levering the pry-off tool against the terminal flange 14 to cause the retaining finger terminals 27 to slide axially outwardly out of retaining engagement with the tire rim.

In making the cover 10, a cover blank B (FIGS. 4 and is initially drawn to provide the crown portion 18, the intermediate portion 19 and in a rudimentary form the outer marginal portion 20 which at this time is preferably lof a generally axially outwardly extending form inoluding a preferably substantially straight portion S joining the radially outer extremity of the intermediate portion 19 on an yannular short radius reinforcing ribjuncture 31. At its axially outer portion the annular cover portion 20 is preferably curved to extend generally radially outwardly, but at this stage of the formation facing generally radially inwardly and axially outwardly. About the outer extremity of the marginal portion 20, at this stage in the manufacture is a cold worked annular peripheral portion W from which extends a plurality of corner marginal portions X from the original preferably polygonal blank of sheet material in which the cover is drawn. It will be noted that the blank of material is of as small dimensions as practicable, vfor purposes of economy, and the drawing is effected in such a manner that the intermediate por-tions of the original edge of the blank run into the peripheral extremity of the circular draw defined by the annular portion W. At the completion of the draw to the extent depicted in FIGURE 5, the sides of the corner portions X merge on a generally concave contour with the peripheral run out of the portion W at the edges of the blank.

The retaining fingers 22 are then blanked out of the corner portions X of the blank B as shown in dash outline in FIGURE 5. In doing this, the side portions of the finger flanges coincide with the original rnill cut or sheared edges of the blank which are substantially burrfree.

Following the blanking out of the fingers 22, the cover blank is subjected to marginal working whereby lthe annular worked portion W is straightened out into preferably substantially cylindrical axially inward position with the finger ii-ange portions also straightened out axially inwardly as unilinear extensions of the portion W. An angular juncture 32 joins the portion W to the annular curved portion 2t). At this time, also, the retaining finger terminal flanges 27 are preferably bent up, `as shown in FIGURE 6.

As a final forming operation, the marginal cover portion 2i) is moved generally radially outwardly into concealing relation -to the retaining fingers and the flange portion 21 is Iturned under from the axially extending marginal portion W. This is preferably effected in shaping die apparatus as shown in FIGURES 7 and 8. In this apparatus, the `cover blank yshaped to the `condition shown in FIGURE 6 is placed in inverted position.

Within the finishing die apparatus, the inverted partially formed cover member is supported upon a vertically reciprocable spring mounted circular supporting member 33 having its supporting surface contoured complementar; to and receptive of the cover crown portion 18 and the cover intermediate portion 19, with the outer periphery of the die member 33 engageable slidably within the cylindrical portion S of the cover blank marginal formation. An upper complementary punch die member 34 engages and clamps the cover crown and intermediate portions 18 and 19 against the lower spring mounted member 33.

Reciprocably slidably disposed about the periphery of the clamping punch member 34 is a holddown member 35 having an annular nose flange depending inner peripheral projection 37 which is contoured to fit with some snugness within the upwardly opening groove defined between the marginal cover portion 20 and 'the axially extending worked marginal extremity flange portion W. By means of the holddown nose ange 37, the cross-sectionally curved cover marginal portion 20 is pressed into an upwardly opening complementary annular transversely curved `forming groove 38 on `a stationary forming die member 39 having an inside diameter 40` substantially the same as the inside diameter of the `cover marginal portion S and providing a reciprocable guide for the spring mounted reciprocable central cover supporting member 33. It will be observed that the inside diameter of the holddown member 35 is substantially the same `as the outside diameter of the cylindrical marginal cover portion S and that the upper clamping and pressing member 34 is of an outside diameter substantially the same as the outside diameter of the cover portion S ifor slidably cooperating with the inner diameter or periphery of the reciprocable holddown member 35.

The construction and relationship of the several die members is such that after the holddown member 35 has been moved downwardly to effect clamping holddown of the cover marginal portion 20 within the shaping groove 38 by means of the holddown nose 37, axially downward pressure exerted by the pressing and pressure member 34 drives the axially extending, cylindrical cover marginal portion S `down into the groove 38 iand `causes the cover marginal portion 20 to work smoothly between the opposing gripping, working surfaces provided by 'the holddown nose member 37 `and the groove 38, with consequent turning and further working of the portion S 4into continuation of the curvature of the marginal p0rtion and until the cover marginal portion 20 has been Worked and moved radially outwardly for concealing disposition relative Ito the retaining finger portions 25, 27 as shown in FIG. 8.

During such working, curling, and axial shortening accompanied by radial projection of the `cover marginal portion 20, the finger portions 22 ofthe axially worked flange portion W are held against distortion and to the diameter thereof by segmental radially reciprocable holding and sizing die members 41 which may be reciprocably supported by the lower die member 39 and have end portions thereot complementary to the outside diameter of the holddown nose portion 37 so that by driving the ends of the segmental die members 41 thereagainst, the cover finger ange portions 22 will be clamped in place. The upper inner corners of the segmental die members 41 are preferably rabbeted or notched out or grooved as at 42 to clear the retaining finger terminals 27. Furthermore, the segmental die members 41 are provided with oblique respective sizing surfaces 43 which overlie the radially outer portions of the forming groove 38 `for sizing the underturned shoulder flange portion 21 as the cover marginal portion 20 is worked radially outwardly in the groove. For this purpose, a bending fulcrum 44 is provided at juncture of the `oblique `surface 43 and the vertical nose end extremity of the segmental `die 41. Through this arrangement, the juncture -rib 23 of the cover iiange is bent about the ulcrum 44 `as the underturned ange portion 21 is swung toward the sizing `surface 43 and the juncture bend 32 becomes progressively more acute. It will be appreciated that there may be as many of the hold-in and sizing segmental die members 41 as preferred which will coact about the entire periphery of the cover blank to hold the nger portions 22 in place during the iinal shaping and sizing.

tAfter the final shaping and sizing has been completed by downward stroke of the pressure die member 34 to the ylimit of movement wherein the cover marginal riblike portion 2t) has been worked and sized and the underturned flange portion 21 has been fully sized, the die members 34 and 35 are backed off and the reciprocable segment dies 41 are backed off and the completed cover removed.

By reason of the substantial and repeated working of the cover marginal lrib portion 20 and the underturned flange 21 a highly resilient marginal structure is provided in cooperation with the stiffly resilient retaining lingers 22 to impart highly effective self-retaining characteristics to the retaining iingers.

By varying the width of the marginal rib of the cover blank and by correspondingly varying the width of the holddown and iforming nose portion of the die mechanism, variations as desired within reasonable limits can be attained in the marginal structure of the cover and more particularly in the underturned marginal flange. Thus, `as depicted by way of example in FIGURES 9 and 10, a shorter underturned flange and thus proportionately longer retaining nger flanges. It will be noted in FIGURES 9 and l0 that except for slightly different proportions in the cover marginal rib and the forming nose rib that fits into it as well as a proportionate shortening of the segment die nose end, the construction and operation are identical with the construction and operation and relationships are the same as in FIGURES 7 and 8. Accordingly, identical reference numerals are used in FIGURES 9 and l0 but primed to diierentiate.

On comparison of FIGURES 7 and 9, it will be observed that the die forming nose portion 37 is somewhat wider than the die nose portion 37. However, the for-ming groove 38 is of the same width and radius as the forming groove l3S. Also, the width of the rib 20 is correspondingly greater than the width of the rib 20. Other proportions and relationships are corelated. The net effect is that the sizing surface 43 is shorter than the sizing surface 43 and the bending fulcrum 44' is closer to the forming `groove 38 than the bending fulcrum 44. Hence, when the die apparatus has functioned to complete working and shaping of the rib 20 as shown in FIGURE l0, the underturned flange 21 is shorter than the corresponding underturned ilange 21. On the other hand, the finger -ange 22 is longer than the finger ange 22.

In FIGURES ll and l2 is shown how through similar die apparatus a substantially wider marginal rib formation on the cover can be worked. In this particular instance, which of course is only exemplary of a substantial range of variation, the marginal rib of the cover is substantially wider while the underturned flange and retaining tinger structure are substantially the same as in the cover 10. In View of the substantial identity of the several related structures, similar reference numerals are applied as in FIGURES 7 and 8 but double primed to distinguish the same.

It will be observed in FIGURES l1 and 12 that the initial width of the annular marginal cover rib 20" is substantially wider than in either of FIGURES 7 or 9 and that the forming groove 38 is substantially larger in radius than the groove 38 or the groove 38. Through this arrangement, in the completed shape of the cover margin as shown in FIGURE 12 at the end of the working stroke of the die members 34 and 33", the marginal rib 26 is substantially wider and shallower than in the forms of the cover described hereinabove. Nevertheless, the underturned marginal iiange 21" may be substantially the same as the underturned flange 21, and the length and shape of the retaining nger iianges 22" substantially the same as the length and shape of the retaining finger flanges 22.

Aiter formation of the cover has been completed, it may be subjected to polishing and plating it desired or other type of nish.

It will be understood that modications and variations may be effected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

l. In apparatus for working a sheet metal circular member having a marginal portion, a iirst pair of die members clampingly engageable with opposite sides of the sheet metal member radially inwardly adjacent to said marginal portion of the sheet metal member, and a second pair of circular die members about said rst mentioned die members, said iirst pair of die members and said second pair of die members being relatively axially movable, one of the members of said second pair of die members having a transversely curved forming groove and the other member of said second pair of die members having a complementary hold-down nose portion engageable within said groove, said nose portion 4pressing isaid sheet metal member margin into said groove, whereby upon relative laxial movement of said iirst pair of die members and said second pair of die members, with the sheet metal member xedly gripped between said lfirst pair of die members, said marginal portion of the sheet metal member will be moved and Worked transversely between and in contact with said nose portion and the curved surface defining said groove.

2. 'In apparatus for working `a sheet metal circular member having a marginal portion, a first pair of die members clampingly engageable with opposite sides or the sheet metal member radially inwardly adjacent to said marginal portion of the sheet metal member, and a second pair of circular die members `about said first mentioned die members, said iirst die members and said second pair of die members being relatively axially movable, one of the members of said second pair of die members having a transversely curved forming groove and the other member of said second pair of die members having a complementary holddown nose portion engageable within said groove, said nose portion pressing said sheet metal member margin into said groove, whereby upon relative axial movement of said lirst pair of die members and said second pair of die members, with the sheet metal member xedly gripped between said first pair of die members, said marginal portion of `the sheet metal member will be moved and worked transversely between and in contact with said nose portion and the curved surface deining said groove, said nose portion having an outside diameter receptive of an axially extending flange on said metal member marginal portion, and die means clampingly engaging said tlange against said surface to retain the same while said marginal portion is worked between said nose portion and -the surface of the groove.

3. In apparatus for working a sheet metal circular member having a marginal portion, a lirst pair of die members clampingly engageable with opposite sides of the sheet metal member radially inwardly adjacent to said marginal portion of the sheet metal member, and a sec* ond pair of circular die members about said first mentioned `die members, said irst pair of die members and said second pair of die members being relatively axially movable, one of the members of said second pair of die members having a transversely curved forming groove and the other member of said second pair of die members having a complementary holddown nose portion engageable within said groove, said nose portion pressing said sheet metal member margin into said groove, whereby upon rel-ative axial movement of said rst pair of die members and said second pair of die members, with the sheet metal member iixedly gripped between `said rst pair of die members, `said marginal portion of the sheet metal member will be moved and worked between said nose portion and the curved surface detining said groove, said nose portion having an outside diameter against which a generally 'axially extending flange on said met-al member marginal portion is adapted to be engaged, and ldie structure engageable with said flange intermediately `of the flange and `spaced from said groove and clamping said flange Iagainst said outside diameter whereby to enable a portion of the ange contiguous said marginal portion `to bend relative to said nose portion during said working of the marginal portion between the nose portion and the surface of the groove.

4. `In apparatus for working a sheet metal circular member having a marginal portion, a first pair of die members clampingly engageable with opposite sides ofthe sheet metal member radially inwardly adjacent to said marginal portion -of `the sheet metal member, and a second pair of circular die members about said rst mentioned die members, said rst pair of die members and said second pair of die members being relatively axially movable, one of the members of said second pair of die members having a transversely curved forming groove and the other member of said second pair of die members having a complementary holddown nose portion engageable within said groove, said nose portion pressing said sheet metal member margin into said groove, whereby upon relative axial movement of said first pair of die members and said second pair of die members, with the sheet metal member tixedly gripped between said rst pair of die members, said marginal portion yof the sheet metal member will be moved and worked between said nose portion and the curved surface defining said groove, said nose portion having an outside diameter against which flange on said metal member marginal portion is adapted to be engaged, and die structure engageable with said flange intermediately of the tiange and spaced from said groove and clamping said ange against said outside diameter whereby to enable a portion of the liange contiguous said marginal portion :to bend relative to said nose portion `during said working `of the marginal portion between the nose portion Iand the surface of the groove, said die structure having a sizing surface thereon disposed `oblquely relative to said outside diameter of the nose portion and engageable by said bendable portion of said flange after the latter has been bent as aforesaid.

References Cited in the le of this patent UNITED STATES PATENTS 2,114,596 Franghi-a Apr. 19, 1938 2,162,734 Lyon June 20, 1939 2,163,003 Lyon June 20, 1939 2,239,897 Lyon Apr. 29, 1941 

